CLEAN-TECH Synergie Group Metal Fines Recycling process
Love for Life
Synergie Group was established in September 2017 in Malta, with the aim of promoting at global level the industrial use of the “CleanTech� tecnology, an innovative and revolutionary step forward in the Electric Arc Furnace (EAF) smelting techniques, applied to inorganic fine dusts and powders, mainly originating from the metal and mining industries, converting these potentially hazardous materials into raw material and ecofriendly inert slag. Mines and metallurgical industries, in fact, generate large quantities of wastes, in a variety of forms, such as dusts, fines, slag, etc., whose recovery, treatment or disposal is difficult and expensive. Thanks to the ability of the "Clean Tech" EAFs to transform these metal wastes and ores in high added value raw materials, avoiding the difficult and costly pre-agglomeration processes, so generating economical advantages to the mining and metal industries, Synergie Group wishes to become a strong, affordable and valuable partner for intelligent environmental solutions.
SYNERGIE G R O U P
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Synergie Group presentation
Designing achieving world
OUR MISSION
and a green
1.
To promote on the European, Asean and US markets the "CleanTech" EAFs.
2.
To project and finance the establishment of recycling centers where the "Clean-Tech" EAFs are applied, for the recovery of fine inorganic wastes generated by the metal and mining industries.
3.
To undertake R&D and engineering activities, with the aim of promoting the further development of the "Clean-Tech" EAFs and their integration with other technologies, in order to achieive projects with zero waste impact and a real circular economy.
CLEAN-TECH
Synergie Group Clean-Tech
Synergie Group Clean-Tech Recycling Process is the innovative recovery system of the stainless steel EAF Dust. Clean-Tech is the future of the recycling of steel fine wastes. It turns a current toxic waste into raw materials for the same steel mills that produced it, generating a virtuose circular economy. Clean-Tech is the most cost effective and performing integrated production system on the market for the recycling of metal fines residues. The integration consists in the adoption of an automated handling and batch system, a Clean Tech furnace combined with a Ezinex hydrometallurgical process. The result is the complete recovery of all the waste metal content in form of valuables by-products. Through the Clean-Tech Recycling Process, Synergie Group is the best ally for steel companies and the best solution to the EAF Dusts and other fine waste related disposal problem.
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Synergie Group presentation
A new environmental technological horizon of Synergie Group
CLEAN-TECH
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Synergie Group presentation
PARTNERS of Clean-Tech
CLEAN-TECH Recycling Center 1
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AIT “Clean-Tech� TECHNOLOGY The AC EA Furnace is managed by a software that regulates the entire Clean-Tech melting process. It calculates the quantities of the metal fines and reagents in the smelt. It automatically regulates the electrodes position, so to constantly maintain the condition for the simultaneous meltingreduction process.
SAET STORAGE & HANDLING SYSTEM The EAF Dusts and the Reagents are separately stored in silos and introduced in the production process according to a recipe pre-calculated by the Clean Tech Software. A system of hoppers, wehiging and mixer will create a homogeneous compound, which will subsequently be placed directly into the EA Furnace, without the need of preagglomeration.
Reactants Lime, silica sand and coke are the reagents used for the EAF Dust redox.
METAL FINES EAF Dust, FA Fines, Metal Ores and Oxides are transported to the Clean-Tech Recycling Center and stored in dedicated silos.
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Synergie Group presentation
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BAG HOUSE The Bag-House collects the highly concentrated ZnO secondary dust from the smelting process fumes. The secondary dust is then transported to the Ezinex plant for the subsequent processing and extraction of the Zn.
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ENGITEC “Ezinex� TECHNOLOGY Secondary dusts are now processed trough the Ezinex plant, an innovative Engitec Technology for the complete recovery of the Zn, based on a hydro metallurgical process.
Zn
99,99% Zn
From the Ezinex process we obtain 99,99% Zn cathodes.
SLAG METAL The metal obtained from the Clean-Tech smelting process is an eco-alloy that will be reused by the waste generator as byproduct or sold to the market as a secondary raw material.
An inert slag is generated by the smelting process. It can be employed as by-product in the cement and rockwool fiber industry.
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PRODUCTS The Recycling Center efficiently recovers more than 95% of the Metal content in form of products (commodities) and by-products suitable for industrial use.
95%
CLEAN-TECH
AIT CLEAN-TECH Technology
CLEAN-TECH Technology AIT CLEAN-TECH Technology is the latest and innovative system for the recovery of metal fines; a real Clean-Tech turning point for the mining and metallurgical sector, thanks to a cutting-edge technology, ideal for environmental and sustainable circular economy initiatives. CLEAN-TECH Technology is an efficient solution, easy to implement thanks to its reduced dimensions, based on a new technological concept applied to electric arc furnaces that allows to directly melt the metal fines without the need for preagglomeration, considerably increasing the profitability of the process.
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Synergie Group presentation
AIT CLEAN-TECH Technology The production process of CLEAN-TECH Technology guarantees to the mining and metallurgical companies a complete exploitation of the dust and fine wastes, definitively solving the problem of their disposal. In the case of steelworks EAF dusts, the technology adopted allows them to be converted in ferroalloy ingots and Zinc Oxide, avoiding pre-agglomeration and without producing toxic waste. The slag obtained from the melting process is an inert material and can be used as raw material for the production of cements or mineral wool. The "Clean-Tech" system ensures a "clean" process, not enabling the processed material and every aspect of the production to release any type of polluting waste in the environment. The beating heart of technology is an electric arc furnace equipped with two technological innovations that allow the direct fusion of metal powders: the DIR (Digital Impedance Regulator), which manages and controls the electric power and the position of the electrodes and finally the TM (Thermodynamic Model) which calculates the recipe of the reagents to be included in the production process. electrical energy of the furnace, and the calibration of the position of the electric arcs that are created between the three electrodes, each time the molten bath increases or decreases level. The AIT PLC is advantageous for its low cost, ease of use, robustness and reliability.
AIT PLC (Programmable Logic Regulator) manages and integrates the entire production process and specifically the functions of the DIR (Digital Impedance Regulator), the TM (Thermodynamic Model). In the specific case, the PLC has the function of constantly regulating the optimal absorption of
AIT “Clean-Tech� - Process Flow Schematic representation of the Process and Procedures Mass Energy Balance
Recipe
Grid Power
PLC Regulator
Bag House
Gases Bag House Dust
Transformer
Market METALS
Reactants Mining & Mineral Processor
Waste Streams
Inert Slag
Clean-Tech
Reactants & Waste
Treated End-Products
CLEAN-TECH
AIT CLEAN-TECH Technology
AIT Clean-Tech technology is applied to AC Electric Arc Furnaces. The electrodes are made of carbon or graphite and powered by three-phase alternating current; The arc is set between the electrodes and the charge; The maximum current density is about 30 A / cm2 for each electrode; The adjustment is carried out by means of a vertical movement of the electrodes driven by an electric or hydraulic motor.
1.0 MVA 2.0 MVA 3.5 MVA 5.0 MVA
AIT EA Furnaces are particularly suitable for the recycling of metal dusts, both in the form of oxides or metal.
MAXIMUM POWER
MAXIMUM POWER
AIT EA Furnaces make it possible to recover over 97% of the metals contained in the dusts.
MAXIMUM POWER
MAXIMUM POWER
Slag On the surface
3 Electrodes PLC Regulator
Arc
4% MAX
(AC)
Permissible Humidity
O Gases
Oxide
Bag-house Filter
Dust Oxides, Metal Fines
Metal
Slag Slagging
Ladle
Slag Granulator
Molten Metal
Arc Electrodes
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Synergie Group presentation
PROGRESSIVE TECHNOLOGY MELT REDUCTION It may look like a straight forward scrap-metal melting furnace where tremendous energy is introduced by electrical arcing in alternating current (AC) mode onto a metallic charge contained in the furnace bowl this via 3 vertical graphite electrodes that are suspended just above the solid charge, but it's PLC-based control system has now been re-conceptualized in such a way (our invention) that, instead of being in melting mode, the furnace has now been transformed into melt-reduction mode wherein a whole range of chemical reactions can now also be introduced to take place, but now involving a non-metallic charge. The AIT Clean-Tech furnace is not the same as a DC (direct current) Plasma-arc furnace, where, by virtue of its single vertically suspended graphite electrode, all the energy is concentrated inside a single long extended arc that is pinned to a tiny small spot on the surface of the molten slag.
HOT TOP FUSION The advantage of AIT Clean-Tech technology is that, because of the extended triply-induced hot arc zone that continuously resides on the surface of the charge – i.e. 'hot-top' mode, materials in the form of finely disseminated particles, i.e. dry fines, can be added to it from above directly and continuously without the necessity of any preliminary capital‐, energy‐ and labour‐ intensive pelletizing or briquetting operation to be in place.
CLEAN-TECH
AIT CLEAN-TECH Technology
INNOVATIVE & PERFORMING ALTERNATING CURRENT AIT Clean-Tech furnace will be operating in AC (alternating current) mode where arcing will be taking place between the tips of the 3 electrodes: the tips now being in slight contact with the slag itself. The fact that electrical power is allowed to pass through the slag between the electrode tips means that resistive heating, besides some openarcing, of the slag will be an additional source of heat energy to the system. ADVANTAGES Easy to operate – this by virtue of our unique PLC-based control system which continuously automatically resets all 3 of the graphite electrodes according to the level of the slowly rising molten bath. Easy to manipulate – any person, even with a secondary-school certificate, can be quickly trained to operate and maintain our furnace. Easy to maintain – occasional new electrode addition/replacement and minor re-patching of worn parts of the refractory lining of the bowl constitutes a large percentage of the furnace maintenance. Versatility - Clean-Tech EAFs can be easily converted from a smelting process to another, according to our TM (Thermodinamic Model).
FURNACE ELECTRICAL PARAMETERS
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Model
CLEAN-TECH 3.5
CLEAN-TECH 5.0
Transformers rating
3.5 MVA
5.0 MVA
Furnaces nominal rating
3.15 MW
4.50 MW
Electrode diameter
250 mm
305 mm
Maximum electrode current
20 kA (UHP)
30 kA
Transformer secondary voltage range
110-200 Volts
110-200 Volts
Synergie Group presentation
TECHNICAL SPECIFICATIONS Model
CLEAN-TECH 3.5
CLEAN-TECH 5.0
Type
Semi-rigid superstructure
Semi-rigid superstructure
Power input
3500 kWA
5000 kWA
Voltage
6.6 to 33 kV 3 ϕ Furnace
6.6 to 33 kV 3 ϕ Furnace
transformer + 550 V/400 V 3 ϕ
transformer + 550 V/400 V 3 ϕ
Auxiliares
Auxiliares
Power factor
Better than 0.9
Better than 0.9
Bowl capacity
13.2 m3
19.05 m3
Bowl size
3.9 m diameter 3.0 m deep
4.5 m diameter 3.0 m deep
Bowl tilting
Fixed
Fixed
Bowl temperature monitoring
16 channel thermocouple
16 channel thermocouple
supervision
supervision
Electrode size
3x250 mm diameter graphite
3x305 mm diameter graphite
Electrode current density 15kA
0.350 A/mm2
0.473 A/mm2
Electrode clamping
Failsafe hydraulically actuated
Failsafe hydraulically actuated
> 80 kN clamping force
> 120 kN clamping force
Fixed, forced water cooled, freezer
Fixed, forced water cooled, freezer
lined
lined
Total length
8m
9m
Total width
5m
5.5 m
Total height
9m
9.5 m
Weight (tined)
70 - 100 tons
70 - 100 tons
Flexible cables
6x10 kA forced water cooled
6x25 kA forced water cooled
annealed copper 8.66 A/mm2. Two
annealed copper 8.8 A/mm2. Two
per electode
per electode
Main control
SCADA system / PLC
SCADA system / PLC
Electrode movement
3xAC motors/vector control drives
3xAC motors/vector control drives
5.5 kW
7.5 kW
11 kW (furnace plus ancillaries)
7.5 kW or as required
Roof
Hydraulic pump
CLEAN-TECH
ENGITEC EZINEX Technology
Engitec Technologies
EZINEX Technology Engitec is very active in the technologies innovation, specially in the field of hydrometallurgy and electrolysis for the production of metals. Its Ezinex, Flubor and Ecuprex processes are the most revolutionary approaches to the extraction and production of Zinc, Lead and Copper of the last twenty years. These innovative technologies have been developed by Engitec technical researchers from the invention phase up to the industrial pilot plant.
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Synergie Group presentation
ENGITEC EZINEX Technology Metallic Zinc recovery from zinc bearing wastes from galvanising industry and from unwashed crude zinc oxide. EZINEX, an acronym derived from “Engitec Zinc Extraction”, was developed by Engitec in Italy since 1993. The basis of the process is a unique hydrometallurgical zinc recovery system that is not sensitive to the typical impurities affecting traditional zinc production. Engitec’s R&D team successfully tested zinc-containing materials from various sources including electric arc furnace (EAF) dust from steel works, Waeltz oxides, oxides from converters and zinc ashes.
Thanks the hydrometallurgical and electrochemical process it is now possible to reach the standards of environmental purity (on micro and macroclimate) already required by the present regulations but not granted by the Phyrometallurgical processes.
The goal of the innovative process are: Low energy levels of the reactions taking place at the electrodes Lower energy waste in the auxiliary operations no more necessary (for example: suction of combustion fumes and reaction gases at high temperature; dusts filtration and separation together with transportation and rework; ventilation system in the working ambient, etc) Reduction of sanitary check on personnel, mainly due to a better ambient environment quality Higher purity of the product
CLEAN-TECH
ENGITEC EZINEX Technology
ENGITEC “Ezinex” Process Flow Schematic representation of the Process and Procedures Residue Recycling in EA Furnace
Residue Cementa on Pb ‐ Cu ‐ Cd
Leaching NH4CI
Bag House Dust Crude Zn Oxides
Residue Separa on Reactor
Filter
Products Reactor
Depleted Solu on Cristallizator Filter
Pb Cements
Purified Solu on
Electrolyte Concentra on Solu on
Concentrate Solu on
Zn Powder
Zinc Cathodes Cell House
Zinc Electrowinning
NaCI KCI
Process description 1. Crude ZnO dust obtained by the pyrometallurgical process of the steel dust is free of FeO and present an high concentration of ZnO (50-60% from austenitic stainless steel, up to 90% from ferritic steel). 2. Crude ZnO dust is stored in a dedicated silos. 3. A leaching step takes place where Zn and some heavy metals are dissolved. By adding Zn powder, heavy metals precipitate (cementation) purifying the solution. 4. The precipitated cements are separated from the purified solution by filtration and are suitable for further recovery of the lead by a smelter. 5. The purified electrolyte is than fed to the EZINEX cells, composed by titanium cathodes and graphite anodes and provided of an air sparging system.
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Synergie Group presentation
At the cathode, Zn is deposited according to the following reaction Zn2+ + 2e > Zn At the anode, the electrochemical chlorine evolution as per the reaction 2Cl2 > Cl2 + 2e is immediately followed by the very fast reaction Cl2 + 2/3NH3 > 1/3N2 + 2HCl converting the chlorine in nitrogen. A single cathode runs at an average of 350 A/m2, producing approx. 7 t/y of Zn. The stripping time is 48 hours. 6. The water balance is kept by a cristallizator, which concentrates the electrolyte and extract the alkali chlorides brought into the solution by the EAF flue dusts.
EZINEX is a ZERO WASTE process. The process outputs have a market destination: Zn - steel industries, metal market Pb cement - Pb smelters Alkali chlorides - secondary aluminium smelters
CLEAN-TECH
SAET Industrial Automation Systems
SAET Technology Founded in 1956 as an electromechanical company SAET diversified later its activities by entering the markets of weighing and dosing systems and, since the early 70's, that one of the industrial automation systems. In the late 80's SAET became part of an important multinational group of engineering and plant engineering, acquiring new working methods and the ability to assume responsability for Turn-Key systems supplies, on the international market too. The company has a technical office with modern facilities, a section of automation that develops its own software applications, and a large factory for construction activities. The research and development, with a traditional partnership with the University of Padua, allows SAET to provide solutions that are technologically advanced.
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Synergie Group presentation
SAET Technology SAET's Operations are divided into these main areas: Energy, Process and Handling. SAET develops Systems and Turn-Key supplies based on the following core competencies : ELECTRICAL SYSTEMS HV Substations, MV-LV Distribution Systems, Protection Metering & Control Systems HANDLING & WEIGHING SYSTEMS * Weighing & Dosing systems, internal Handling systems INDUSTRIAL AUTOMATION SYSTEMS * PLC & DCS control systems, SCADA systems. During more than 50 years, SAET accumulated an important expertise into the areas of Energy, Cement, Iron&Steel and Raw materials, often collaborating with Engineering & Contracting companies and always taking care of the Customer Satisfaction.
CLEAN-TECH
Love for Life
SYNERGIE G R O U P
WWW.SYNERGIE.IO Synergie Group Ltd Headquarters: 1 Floor 2, Falzun Str., c/w Naxxar Road - Birkirkara BKR 1441 - MALTA Operative Office: Via Pastrengo, 12/1 - 16122 Genova (GE) - ITALY info@synergie.io
SYNERGIE G R O U P